Process For The Production Of Polyurethane Composite Components

Abstract

The invention relates to a process for the production of a composite component, comprising a) a support of a thermoplastic composition, and b) at least one polyurethane layer in direct contact with the support. The process involves (i) in a first process step the melt of the thermoplastic composition is injected into a first mould cavity and is subsequently cooled, the thermoplastic composition comprising: A) 65.0 to 90.0 parts by wt., based on the sum of components A and B, of at least one polymer chosen from the group of aromatic polycarbonates, aromatic polyester carbonates and aromatic polyesters, B) 10.0 to 35.0 parts by wt., based on the sum of components A and B, of an optionally rubber-modified vinyl (co)polymer and C) 0 to 30.0 parts by wt., based on the sum of components A to C, of at least one commercially available polymer additive, And (ii) in a second process step the cavity of the injection mould is enlarged and a gap is thereby generated, and (iii) in the third process step a reactive polyurethane raw material mixture comprising at least one polyisocyanate component, at least one polyfunctional H-active compound, and optionally at least one polyurethane additive and/or process auxiliary substance is injected into the gap resulting in this way between the thermoplastic component and the mould surface of the enlarged cavity, the polyurethane raw material mixture polymerizing completely in contact with the surface of the thermoplastic support to give a compact polyurethane layer or to give a polyurethane foam layer. And (iv) in a fourth process step the composite component is removed from the mould cavity. Preferably the process steps following one another directly.

1 . A process for the production of a composite component, said component comprising
 a) a support of a thermoplastic composition, and   b) at least one polyurethane layer in direct contact with the support, wherein said process comprises
 (i) in a first process step, injecting a melt of the thermoplastic composition into a first mould cavity and subsequently cooling, the thermoplastic composition comprising 
 A) 65.0 to 90.0 parts by wt., based on the sum of components A and B, of at least one polymer selected from the group consisting of aromatic polycarbonates, aromatic polyester carbonates and aromatic polyesters, 
 B) 10.0 to 35.0 parts by wt., based on the sum of components A and B, of an optionally rubber-modified vinyl (co)polymer and 
 C) 0 to 30.0 parts by wt., based on the sum of components A to C, of at least one polymer additive, 
 (ii) in a second process step, enlarging a cavity of the injection mould to thereby generate a gap therein, 
 (iii) in the third process step, injecting into said gap, a reactive polyurethane raw material mixture comprising 
   at least one polyisocyanate component,   at least one polyfunctional H-active compound, and   optionally at least one polyurethane additive and/or process auxiliary   
       whereby the polyurethane raw material mixture is capable of polymerizing completely in contact with a surface of the thermoplastic support to give a compact polyurethane layer and/or to give a polyurethane foam layer,
   (iv) in the fourth process step, removing the composite component from the mould cavity, And further wherein the process steps directly follow one another.   
 
     
     
         2 . A process according to  claim 1 , wherein the reactive polyurethane raw material mixture has a characteristic number of from >90 to <125. 
     
     
         3 . A process according to  claim 1 , wherein a mixture of at least one aromatic polycarbonate and/or polyester carbonate and at least one aromatic polyester is employed as component A. 
     
     
         4 . A process according to  claim 1 , wherein the composition of the support material comprises 70.0 to 80.0 parts by wt. of component A, based on the sum of components A and B. 
     
     
         5 . A process according to  claim 1 , wherein process steps (ii) and (iii) are repeated at least once with variation of the polyurethane system. 
     
     
         6 . A process according to  claim 1 , wherein in process step (iii), a surface of the injection mould in contact with the thermoplastic composition is temperature-controlled at a temperature from 50 to 95° C., and a surface of the injection mould in contact with the reactive polyurethane mixture is temperature-controlled at a temperature from 50 to 160° C. 
     
     
         7 . A process for the production of a composite component, said component comprising
 a) a support of a thermoplastic composition and   b) at least one polyurethane layer in direct contact with the support, wherein said process comprising:
 (i) in a first process step, injecting a melt of the thermoplastic composition into a first mould cavity and subsequently cooling, 
 (ii) in a second process step, enlarging a cavity of the injection mould to generate a gap therein, 
 (iii) in a third process step, injecting a reactive polyurethane raw material mixture comprising 
   at least one polyisocyanate component,   at least one polyfunctional H-active compound, and   optionally at least one polyurethane additive and/or process auxiliary substance into the gap, whereby the polyurethane raw material mixture polymerizes completely in contact with a surface of the thermoplastic support to give a compact polyurethane layer and/or to give a polyurethane foam layer,
 (iv) in the fourth process step, removing the composite component from the mould cavity, wherein process steps (ii) and (iii) can be passed through several times, the process steps directly follow one another, and in process step (iii), the temperature of the mould cavity on the polyurethane side is at least 10° C. higher than the temperature of the mould cavity on the support side where the thermoplastic is provided. 
   
     
     
         8 . A two- or multicomponent part, coated with at least one polyurethane produced from a composition comprising
 A) 65.0 to 90.0 parts by wt., based on the sum of components A and B, of at least one polymer selected from the group consisting of aromatic polycarbonates, aromatic polyester carbonates and aromatic polyesters,   B) 10.0 to 35.0 parts by wt., based on the sum of components A and B, of an optionally rubber-modified vinyl (co)polymer and   C) 0 to 30.0 parts by wt., based on the sum of components A to C, of at least one commercially available polymer additive.   
     
     
         9 . A part according to  claim 8 , wherein a mixture of at least one aromatic polycarbonate and/or polyester carbonate and at least one aromatic polyester is employed as component A. 
     
     
         10 . A composite component comprising
 a) a support of a composition comprising
 A) 65.0 to 90.0 parts by wt., based on the sum of components A and B, of at least one polymer chosen from the group of aromatic polycarbonates, aromatic polyester carbonates and aromatic polyesters, 
 B) 10.0 to 35.0 parts by wt., based on the sum of components A and B, of an optionally rubber-modified vinyl (co)polymer and 
 C) 0 to 30.0 parts by wt., based on the sum of components A to C, of a commercially available polymer additive and 
   b) at least one polyurethane layer in direct contact with the support, produced in a 2-component injection moulding or 2-component reactive injection moulding process.   
     
     
         11 . A composite component according to  claim 10 , wherein component A comprises a mixture of at least one aromatic polycarbonate and/or polyester carbonate and at least one aromatic polyester. 
     
     
         12 . A composite component according to  claim 10 , produced in a 2-component reactive injection moulding process with a reactive polyurethane raw material mixture comprising
 at least one polyisocyanate component,   at least one polyfunctional H-active compound, and   optionally at least one polyurethane additive and/or process auxiliary substance   
       Wherein the reactive polyurethane raw material mixture has a characteristic number of from >90 to <125. 
     
     
         13 . A composite component produced by a process according to  claim 1 . 
     
     
         14 . A composite component according to  claim 10 , wherein component C is at least one selected from the group consisting of flameproofing agents, flameproofing synergists, smoke-suppressing additives, antidripping agents, internal and external lubricants and mould release agents, flowability auxiliary agents, antistatics, conductivity additives, nucleating agents, stabilizers, antibacterially acting additives, additives which improve scratch resistance, IR absorbents, optical brighteners, fluorescent additives, fillers and reinforcing substances, dyestuffs and pigments, impact modifiers which do not fall under the definition of B.1, and Brønstedt acid compounds. 
     
     
         15 . An interior and/or exterior component of a track, air travel or motor vehicle comprising a composite component of  claim 10 . 
     
     
         16 . An interior and/or exterior component of a track, air travel or motor vehicle comprising a composite component of  claim 11 . 
     
     
         17 . An interior and/or exterior component of a track, air travel or motor vehicle comprising a composite component of  claim 12 . 
     
     
         18 . An interior and/or exterior component of a track, air travel or motor vehicle comprising a composite component of  claim 13 . 
     
     
         19 . An interior and/or exterior component of a track, air travel or motor vehicle comprising a composite component of  claim 14 .